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Details of Grant 

EPSRC Reference: GR/N14132/01
Title: INTEGRATED PROCESS MODELLING FOR GAS TURBINE MANUFACTURE
Principal Investigator: McLean, Dr M
Other Investigators:
Lee, Professor P
Researcher Co-Investigators:
Project Partners:
Rolls-Royce Plc (UK) Special Metals Wiggin Trustees Ltd Wyman-Gordon Ltd
Department: Materials
Organisation: Imperial College London
Scheme: Standard Research (Pre-FEC)
Starts: 01 September 2000 Ends: 29 February 2004 Value (£): 222,533
EPSRC Research Topic Classifications:
Materials Processing
EPSRC Industrial Sector Classifications:
Manufacturing Electronics
Aerospace, Defence and Marine
Related Grants:
GR/N14163/01 GR/N14101/01
Panel History:  
Summary on Grant Application Form
Stringent targets for fuel efficiency, performance and emission control in modern gas turbines lead to extreme conditions of temperature, atmosphere and stress in the engine, requiring Ni superalloy discs in the turbine and final stages of the compressor. These discs need to have exceptional integrity, especially for aerospace applications, which means that the manufacturing route has to be highly regulated to ensure conformity to the engineering and design requirements. The manufacturing route involves five key stages: (1) vacuum arc remelting (VAR), (2) cogging, (3) forging, (4) heat treatment and (5) machining. The overall aim of the present proposal is to use numerical modelling techniques combined with experimental trials to develop a fundamental understanding of defect, microstructure and residual stress control during the manufacture of Ni alloy discs. By the end of the 3 year programme, we will be able to predict the disc critical features by transferring modelling results from VAR through to final machining. The fundamental research will be carried out by Imperial, the IRC, Birmingham and the Cambridge UTC, in collaboration with industrial partners along the supply chain Special Metals (VAR and cogging), Wyman Gordon Limited (forging and heat treatment), and Rolls Royce plc (machining and end-user).EngProg\
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Organisation Website: http://www.imperial.ac.uk